Test Equipment Depot - 800.517.8431-99 Washington Street Melrose, MA 02176 TestEquipmentDepot.com P5523 Liquid to Gas Separator Users Manual PN 3952355 November 2010 2010 Fluke Corporation. All rights reserved. Printed in USA. Specifications are subject to change without notice. All product names are trademarks of their respective companies.
LIMITED WARRANTY AND LIMITATION OF LIABILITY Each Fluke product is warranted to be free from defects in material and workmanship under normal use and service. The warranty period is one year and begins on the date of shipment. Parts, product repairs, and services are warranted for 90 days. This warranty extends only to the original buyer or end-user customer of a Fluke authorized reseller, and does not apply to fuses, disposable batteries, or to any product which, in Fluke's opinion, has been misused, altered, neglected, contaminated, or damaged by accident or abnormal conditions of operation or handling. Fluke warrants that software will operate substantially in accordance with its functional specifications for 90 days and that it has been properly recorded on non-defective media. Fluke does not warrant that software will be error free or operate without interruption. Fluke authorized resellers shall extend this warranty on new and unused products to end-user customers only but have no authority to extend a greater or different warranty on behalf of Fluke. Warranty support is available only if product is purchased through a Fluke authorized sales outlet or Buyer has paid the applicable international price. Fluke reserves the right to invoice Buyer for importation costs of repair/replacement parts when product purchased in one country is submitted for repair in another country. Fluke's warranty obligation is limited, at Fluke's option, to refund of the purchase price, free of charge repair, or replacement of a defective product which is returned to a Fluke authorized service center within the warranty period. To obtain warranty service, contact your nearest Fluke authorized service center to obtain return authorization information, then send the product to that service center, with a description of the difficulty, postage and insurance prepaid (FOB Destination). Fluke assumes no risk for damage in transit. Following warranty repair, the product will be returned to Buyer, transportation prepaid (FOB Destination). If Fluke determines that failure was caused by neglect, misuse, contamination, alteration, accident, or abnormal condition of operation or handling, including overvoltage failures caused by use outside the product s specified rating, or normal wear and tear of mechanical components, Fluke will provide an estimate of repair costs and obtain authorization before commencing the work. Following repair, the product will be returned to the Buyer transportation prepaid and the Buyer will be billed for the repair and return transportation charges (FOB Shipping Point). THIS WARRANTY IS BUYER'S SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FLUKE SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR LOSSES, INCLUDING LOSS OF DATA, ARISING FROM ANY CAUSE OR THEORY. Since some countries or states do not allow limitation of the term of an implied warranty, or exclusion or limitation of incidental or consequential damages, the limitations and exclusions of this warranty may not apply to every buyer. If any provision of this Warranty is held invalid or unenforceable by a court or other decision-maker of competent jurisdiction, such holding will not affect the validity or enforceability of any other provision. Fluke Corporation P.O. Box 9090 Everett, WA 98206-9090 U.S.A. Fluke Europe B.V. P.O. Box 1186 5602 BD Eindhoven The Netherlands 11/99 To register your product online, visit register.fluke.com
Table of Contents Title Page General Information... 1 How to Contact Fluke... 2 Safety Summary... 2 Compressed Liquid & Gas... 2 Personal Protective Equipment... 2 Symbols Used in this Manual... 2 Preparations... 3 Connect the Gauge... 4 Connect the Test Port Insert... 4 Priming... 5 Operation... 6 Disconnecting the Unit from the Deadweight Tester... 6 Ancillary Equipment... 7 Angle Adapter, P5543... 7 Pointer Remover/Punch, P5551... 7 i
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List of Tables Table Title Page 1. Symbols... 2 2. Test Port Insert - Parts List... 5 iii
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List of Figures Figure Title Page 1. Hydraulic/Pneumatic Circuit Schematic... 1 2. Connecting the Gauge... 4 3. Test Port Insert... 5 4. Angle Adapter... 7 5. Pointer Remover/Punch... 7 v
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General Information The P5523 is used for calibrating high-pressure gas measuring instruments against a hydraulic Deadweight Tester. Note The terms Master Test Gauge and Gauge in this document refer to any pressure-measuring instrument such as Transfer Standards, Digital Calibrators and Transducers. An external high-pressure gas source is applied through a series of liquid traps, to the hydraulic system of the deadweight tester. Typically, dry Nitrogen from a commercially available compressed gas cylinder is used. With the deadweight tester system correctly primed, gas pressure from the external supply is adjusted to reach equilibrium with the weights on the deadweight tester. 5523 SEPARATOR Figure 1. Hydraulic/Pneumatic Circuit Schematic gle01.eps 1
P5523 Users Manual How to Contact Fluke To order accessories, receive operating assistance, or get the location of the nearest Fluke distributor or Service Center, call: Technical Support USA: 1-800-99-FLUKE (1-800-993-5853) Calibration/Repair USA: 1-888-99-FLUKE (1-888-993-5853) Canada: 1-800-36-FLUKE (1-800-363-5853) Europe: +31-402-675-200 China: +86-400-810-3435 Japan: +81-3-3434-0181 Singapore: +65-738-5655 Anywhere in the world: +1-425-446-5500 Or, visit Fluke's website at www.fluke.com. To register your product, visit http://register.fluke.com. To view, print, or download the latest manual supplement, visit http://us.fluke.com/usen/support/manuals. Safety Summary The following are general safety precautions that are not related to any specific procedures and do not appear elsewhere in this publication. These are recommended precautions that personnel must understand and apply during equipment operation and maintenance to ensure safety and health and protection of property. Compressed Liquid & Gas Use of compressed liquids and gasses can create an environment of propelled foreign matter. Pressure system safety precautions apply to all ranges of pressure. Care must be taken during testing to ensure that all hydraulic and pneumatic connections are properly and tightly made prior to applying pressure. Personnel must wear eye protection to prevent injury. Personal Protective Equipment Wear eye protection approved for the materials and tools being used. Symbols Used in this Manual In this manual, a Warning identifies conditions and actions that pose a hazard to the user. A Caution identifies conditions and actions that may damage the Liquid to Gas Separator. Symbols used on the Liquid to Gas Separator and this manual are explained in Table 1. Table 1. Symbols Symbol B J W ~ Description AC (Alternating Current) Earth Ground Important Information: refer to manual Do not dispose of this product as unsorted municipal waste. Go to Fluke s website for recycling information. 2
Liquid to Gas Separator Preparations Preparations This section assumes that the deadweight tester is completely primed with the correct fluid. The P5523 should be placed on a level, stable workbench or similar surface, to the right-hand side of the deadweight tester. Level the P5523 using the four adjustable feet to prevent rocking, and fit the connection hose supplied with the instrument to the bulkhead coupling on the top plate. The other end of the hose must be attached the test port of the deadweight tester in the same manner as a conventional pressure gauge or transducer. The hose is pre-assembled with a flat-faced fitting for this purpose; see notes below on making correct connections. The external gas supply is connected to the ¼ NPT port in the rear of the P5523 case. A compressed gas cylinder fitted with a suitable pressure regulator is recommended. Factory (compressor) air lines or gas multipliers should only be used if a series of filters are fitted to ensure that the supply is clean and dry. W Caution The external pressure supply must be regulated to either the maximum range of the P5523 (3000 psi / 210 bar), or 10% above the maximum pressure required, whichever is the lower. DO NOT OVER-PRESSURIZE THE P5523. Fit the device under test (DUT) to the test port using the method described below: W Caution Ensure that all devices are internally clean and free from contamination before connecting to the tester. Particle contamination can damage valve seats. W Warning DO NOT use Teflon/PTFE tape on these connections, as this will prevent correct sealing. The Gauge Adapter sealing system is designed for hand-tight sealing up to 20,000 psi / 1,400 bar-wrenches or similar tools are not required over tightening can cause damage to threads or sealing faces. Before connection, ensure that there is an O-ring fitted to the test port. Check that the sealing face of the device to be fitted is clean and undamaged, as scratches or dents can form leak-paths. Note The thread on the test port, and the lower part of the gauge adapters is LEFT-HANDED. The following procedure details the correct method for mounting devices using these adapters. 3
P5523 Users Manual 1 2 3 4 Figure 2. Connecting the Gauge gle11.eps Connect the Gauge Refer to Figure 2 for steps 1-4. 1. Screw the appropriate gauge adapter fully on to the instrument to be tested. 2. Screw assembly down COUNTER-CLOCKWISE onto test port. Note Hand-tight is sufficient; ensure that the bottom face contacts the O-ring on the test port. 3. To adjust the position to face forward, hold the gauge adapter and turn the instrument COUNTER-CLOCKWISE, so that it faces forward. 4. Hold the instrument steady, while turning the gauge adapter COUNTER-CLOCKWISE until it pulls down onto the O-ring. Connect the Test Port Insert For devices with 1/8 BSP or NPT mounting threads, the diameter of the thread is very close to the effective sealing diameter of the O-ring fitted to the test port. This can make it difficult to achieve a good seal. When mounting these devices, use the test port insert (stored in the spare seals container) as shown in Figure 3. 4
Liquid to Gas Separator Priming 1 2 3 4 Figure 3. Test Port Insert gle012.eps Table 2. Test Port Insert - Parts List Item Description Part Number 1 O Ring 3865142 2 Test Port Insert 3919892 3 O Ring 3883397 4 Test Port To calibrate panel-mounted gauges with pressure connections in the rear, use an Angle Adapter. (Refer to section, Ancillary Equipment.) Priming 1. Unscrew and remove reservoir cap from left-hand reservoir. Note the position of the groove inside the reservoir body this is the Fluid Datum Level. 2. Using the priming pump on the deadweight tester, slowly drive fluid from the deadweight tester through the connection pipe, into the left-hand reservoir, until it is just below the Fluid Datum Level. 3. Allow a few moments for the system to stabilize, and then bring the fluid up to the Datum Level by slowly turning the screw press in (clockwise). 5
P5523 Users Manual 6 Note The fluid height must not be above this level during operation turn the screw press out (counter-clockwise) to reduce the fluid level. 4. Replace the reservoir cap. Operation W Warning ALWAYS reduce the system pressure with the Exhaust Valve NEVER use the deadweight tester reservoir valve. 1. Ensure both Inlet and Exhaust valves are closed. 2. Place the weights necessary to achieve the desired calibration point on the deadweight tester. 3. Slowly open and close the inlet valve until the piston floats. To avoid over-pressurization due to fluid-stick, the weights can be gently rotated close to the calibration point. The monitor gauge fitted to the separator can be used as a guide to the system pressure. 4. Use the screw press for fine adjustment of the PCU float height do not turn screw press more than 2 turns in or out from its priming position. 5. Ensure that the weights are rotating freely, and allow a few moments for the system to stabilize before taking any readings, especially after large changes in system pressure. Note Large, sudden changes in pressure will cause the system temperature to rise or fall, which can cause instrument readings to change as the fluid in the system expands or contracts, thus increasing or decreasing the pressure. 6. Compare the reading of the gauge under test with that of the master gauge. 7. For the next, higher calibration point, repeat from step 2 above. 8. To measure reducing pressures, remove the necessary weights from the deadweight tester, and slowly open and close exhaust valve, reducing the system pressure until the piston is floating at its mid-operating position. 9. Ensure that the weights are rotating freely, and allow a few moments for the system to stabilize before taking any readings. 10. During long periods of use, the fluid level in the left-hand reservoir should be checked, and adjusted if necessary, to maintain the correct datum level. Ensure that the system is FULLY DEPRESSURIZED before removing the reservoir cap. 11. To depressurize the system fully, slowly open and close the exhaust valve NEVER depressurize the system quickly. Disconnecting the Unit from the Deadweight Tester 1. With the system fully depressurized, remove the reservoir cap from the left-hand reservoir. 2. Ensure reservoir valve is closed on the deadweight tester, and turn the screw press out to draw fluid back into the deadweight tester reservoir. (Observe fluid level in P5523 reservoir.)
Liquid to Gas Separator Ancillary Equipment 3. When the fluid has been withdrawn from the separator, the connection hose can be disconnected from the deadweight tester. Periodically, the right-hand reservoir body should be inspected and cleaned, to remove any fluid that may be present. Ancillary Equipment Angle Adapter, P5543 To calibrate gauges with the pressure connection on the rear (e.g. panel-mount gauges) in their correct position, an angle adapter should be used. The angle adapter fits directly onto the test station, converting it through 90 degrees, allowing the standard adapters to be used. Figure 4. Angle Adapter gle09.bmp Pointer Remover/Punch, P5551 To remove and refit the pointer of a pressure gauge, use the Pointer Remover/Punch. This tool has a spring-loaded plunger to quickly and consistently refit the pointer. Figure 5. Pointer Remover/Punch gle10.bmp 7
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